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Koolaire STH045 8/15 Technician's Handbook

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KOOLAIRE
Ice Machines
Technician's
Handbook
This manual is updated as new information and models are
released. Visit our website for the latest manual. www.kool-aire.com
Part Number STH045 8/15

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Summary of Contents for Koolaire STH045 8/15

  • Page 1 KOOLAIRE Ice Machines Technician’s Handbook This manual is updated as new information and models are released. Visit our website for the latest manual. www.kool-aire.com Part Number STH045 8/15...
  • Page 3 Safety Notices As you work on Koolaire equipment, be sure to pay close attention to the safety notices in this handbook. Disregarding the notices may lead to serious injury and/or damage to the equipment. Throughout this handbook, you will see the following...
  • Page 4 Procedural Notices As you work on Koolaire equipment, be sure to read the procedural notices in this handbook. These notices supply helpful information which may assist you as you work. Throughout this handbook, you will see the following types of procedural notices:...
  • Page 5 Warning Do not use electrical appliances or accessories other than those supplied by Koolaire for your ice machine model. Warning Two or more people or a lifting device are required to lift this appliance.
  • Page 6 Warning This equipment contains high voltage electricity and refrigerant charge. Installation and repairs are to be performed by properly trained technicians aware of the dangers of dealing with high voltage electricity and refrigerant under pressure.The technician must also be certified in proper refrigerant handling and servicing procedures.
  • Page 7 Warning Do not obstruct machine vents or openings. Warning Do not store gasoline or other flammable vapors or liquids in the vicinity of this or any other appliance. Warning Do not clean with water jet. Warning It is the responsibility of the equipment owner to perform a Personal Protective Equipment Hazard Assessment to ensure adequate protection during maintenance procedures.
  • Page 8 Warning When using electric appliances, basic precautions must always be followed, including the following: a. Read all the instructions before using the appliance. b. To reduce the risk of injury, close supervision is necessary when an appliance is used near children. c.

  • Page 9: Table Of Contents

    Removal from Service/Winterization . . . 43 Air-cooled Models ....43 Water-cooled Models ... . . 43 Part Number STH045 8/15...
  • Page 10 Discharge Line Temperature Analysis . 79 Refrigeration Component Diagnostics . 81 Final Analysis ....83 Refrigeration Component Diagnostic Chart Part Number STH045 8/15...
  • Page 11 Procedure ..... . 116 Replacing Pressure Controls without Removing Refrigerant Charge ..117 Refrigerant Amount ....119 Part Number STH045 8/15...
  • Page 12 Electronic Control Board ... 144 Refrigeration Tubing Schematics ..145 Self-contained Air or Water-cooled . . . 145 Remote Air-cooled ....146 Part Number STH045 8/15...

  • Page 13: General Information

    KD0350A KD0350W ---- KY0350A KY0350W ---- KD0420A KD0420W ---- KY0420A KY0420W ---- KD0500A KD0500W ---- KY0500A KY0500W ---- KD0600A KD0600W ---- KY0600A KY0600W ---- KD1000A KD1000W KY1000N KY1000A KY1000W KD1000N KD1350A KD1350W KY1350N KY1350A KY1350W KD1350N Part Number STH045 8/15...

  • Page 14: How To Read A Model Number

    N - Remote Air-cooled Warning An ice machine contains high voltage electricity and refrigerant charge. Repairs are to be performed properly trained refrigeration technicians aware of the dangers of dealing with high voltage electricity and refrigerant under pressure. Part Number STH045 8/15...

  • Page 15: Ice Machine Warranty Information

    Distributor as the first day of warranty coverage for your new ice machine. COMMERCIAL WARRANTY COVERAGE The Koolaire brand warranty is administered through Manitowoc Ice (hereinafter referred to as the “COMPANY”) warrants for a period of 36 months from the installation date (except as limited below) that new...
  • Page 16 Upon the expiration of the warranty period, the COMPANY’s liability under this warranty shall terminate. The foregoing warranty shall constitute the sole liability of the COMPANY and the exclusive remedy of the customer or user. Part Number STH045 8/15...
  • Page 17 Authorized Warranty Service To comply with the provisions of the warranty, a refrigeration service company qualified and authorized by your Koolaire distributor, or a Factory Authorized Servicer must perform the warranty repair. Service Calls Normal maintenance, adjustments and cleaning as outlined in this manual are not covered by the warranty.

  • Page 18: Residential Warranty Coverage

    Manitowoc’s liability under this limited warranty is limited to the purchase price of Product. Additional expenses including, without limitation, service travel time, overtime or premium labor charges, accessing or removing the Product, or shipping are the responsibility of the consumer. Part Number STH045 8/15...
  • Page 19 HOW TO OBTAIN WARRANTY SERVICE To obtain warranty service or information regarding your Koolaire product, please contact: MANITOWOC ICE 2110 So. 26th St. P.O. Box 1720, Manitowoc, WI 54221-1720 Telephone: 920-682-0161 Fax: 920-683-7585 www.kool-aire.com WHAT IS NOT COVERED? This limited warranty does not cover, and you are...
  • Page 20 Manitowoc within thirty (30) days from the sale date. Complete the following registration card and send it to Manitowoc. For factory assistance Contact: Manitowoc Foodservice Ice Machine Division 2110 South 26 Street, PO Box 1720, Manitowoc WI, 54221-1720 Telephone: 920-682-0161 Fax: 920-683-7585 Website: www.kool-aire.com Part Number STH045 8/15...

  • Page 21: Limited Warranty For Ice Storage Bins

    Limited Warranty for Ice Storage Bins LIMITED WARRANTY Koolaire®, a division of Manitowoc FSG Operations, LLC (“Company”), warrants the new Ice Storage Bin sold by Company shall be free of defects in material or workmanship under normal and proper use and...
  • Page 22 This Limited Warranty shall not apply if the Ice Storage Bin is modified with parts and assemblies other than those manufactured by the Company, unless the Company approves these modifications for specific locations in writing prior to the commencement of the modification. Part Number STH045 8/15...
  • Page 23 Company with respect to any item or unit or equipment or services shall be deemed a breach with respect to any item or unit of equipment or services shall be deemed a breach with respect to that item or unit or service only. Part Number STH045 8/15...
  • Page 24 All Warranty service must be performed by an approved Koolaire contracted or authorized Service Representative. To schedule a service appointment contact your local Koolaire Service Representative or visit us at www.kool-aire.com to find a Service Representative near you. GOVERNING LAW...

  • Page 25: Installation

    Refer to the chart for clearance requirements. • The ice machine must be protected if it will be subjected to temperatures below 32°F (0°C). Failure caused by exposure to freezing temperatures is not covered by the warranty. Part Number STH045 8/15...

  • Page 26: Ice Machine Clearance Requirements

    ! Caution The ice machine must be protected if it will be subjected to temperatures below 32°F (0°C). Failure caused by exposure to freezing temperatures is not covered by the warranty. Part Number STH045 8/15...

  • Page 27: Ice Machine Heat Of Rejection

    The legs must be screwed in tightly to prevent them from bending. 2. Move the bin into its final position. 3. Use a level on top of the bin. Adjust each foot as necessary and level from front to back and side to side. Part Number STH045 8/15...

  • Page 28: Electrical Requirements

    The ice machine data plate information overrides all other published data. Warning All wiring must conform to local, state and national codes. Warning The ice machine must be grounded in accordance with national and local electrical code. Part Number STH045 8/15...

  • Page 29: Water Service/Drains

    (Check valves on sink faucets, dishwashers, etc.) • If water pressure exceeds the maximum recommended pressure, 80 psig (5.5 bar) obtain a water pressure regulator from your Koolaire distributor. • Install a water shut-off valve for ice making potable water.

  • Page 30: Drain Connections

    Allow for a pressure drop of 7 psig (.48 bar) between the condenser water inlet and the outlet of the ice machine. • Water exiting the condenser must not exceed 110°F (43.3°C). ! Caution Plumbing must conform to state and local codes Part Number STH045 8/15...
  • Page 31 WATER SUPPLY AND DRAIN LINE SIZING/ CONNECTIONS Part Number STH045 8/15...
  • Page 32 This Page Intentionally Left Blank Part Number STH045 8/15...

  • Page 33: Maintenance

    Read and understand all labels printed on bottles before use. CLEANING AND SANITIZING PROCEDURE Ice machine cleaner is used to remove lime scale and mineral deposits. Ice machine sanitizer disinfects and removes algae and slime. Part Number STH045 8/15...

  • Page 34: Toggle Switch Operation

    Never use anything to force ice from the evaporator. Damage may result. Step 2 Remove all ice from the bin. Warning Wear rubber gloves and safety goggles (and/or face shield) when handling Ice Machine Cleaner or Sanitizer. Part Number STH045 8/15...
  • Page 35 Step 5 Remove parts for cleaning. Refer to the proper parts removal for your machine. Continue with step 6 when the parts have been removed. Part Number STH045 8/15...
  • Page 36 Use a nylon brush or cloth to thoroughly clean the following ice machine areas: • Evaporator plastic parts – including top, bottom and sides • Bin bottom, sides and top • Rinse all areas thoroughly with clean water. Part Number STH045 8/15...
  • Page 37 K0250 K0350 K0420 3 ounces (90 ml) K0500 K0600 K1000 K1350 6 ounces (180 ml) Wait until the sanitize cycle is complete (approximately 24 minutes) then place the toggle switch in the ice position to start ice making. Part Number STH045 8/15...

  • Page 38: Remove Parts For Cleaning

    • Disassemble distribution tube by loosening the two (2) middle thumbscrews and dividing the distribution tube into two pieces. • Proceed to page 36 Step 6. Part Number STH045 8/15...
  • Page 39 Depress tabs on right and left side of the water trough. • Allow front of water trough to drop as you pull forward to disengage the rear pins. • Remove the water trough from the bin area. Part Number STH045 8/15...

  • Page 40: Preventative Maintenance Cleaning

    3 ounces (90 ml) K0500 K0600 K1000 5 ounces (150 ml) K1350 9 ounces (265 ml) Step 3 Wait until the clean cycle is complete (approximately 24 minutes) then place the toggle switch in the off position. Part Number STH045 8/15...

  • Page 41: Ice Machine Inspection

    Sponge any dust and dirt off the outside of the ice machine with mild soap and water. Wipe dry with a clean, soft cloth. Cleanup any fallen ice or water spills as they occur. Part Number STH045 8/15...

  • Page 42: Cleaning The Condenser

    Shine a flashlight through the condenser to check for dirt between the fins. • Blow compressed air or rinse with water from the inside out (opposite direction of airflow). • If dirt still remains call a service agent to clean the condenser. Part Number STH045 8/15...

  • Page 43: Removal From Service/Winterization

    2. Disconnect the incoming water and drain line from the water-cooled condenser. 3. Energize the ice machine in the freeze cycle. The increasing refrigerant pressure will open the water regulating valve. 4. Blow compressed air through the condenser until no water remains. Part Number STH045 8/15...
  • Page 44 This Page Intentionally Left Blank Part Number STH045 8/15...

  • Page 45: Ice Making Sequence Of Operation

    Full Bin Cycle If the water curtain is held open by ice cubes the ice machine shuts off. When the water curtain closes the ice machine starts a new cycle at the water purge. Part Number STH045 8/15...

  • Page 46: Control Board Timers

    After 3 consecutive 60 minute cycles control board light SL#1 light will flash on/off at 1 second intervals. • If 6 consecutive 60-minute freeze cycles occur, the ice machine stops and the SL#1 light on the control board will be on continuously. Part Number STH045 8/15...
  • Page 47 If 100 consecutive failures occur the ice machine stops and the SL#1 & SL#2 lights flash on/off at 1 second intervals. • SL#1 & SL#2 will flash 3 times on startup and automatically erase after 100 normal cycles. Part Number STH045 8/15...

  • Page 48: Energized Parts Chart

    ENERGIZED PARTS CHART Self-Contained Ice Machines Compressor ICE MAKING (Contactor) & SEQUENCE OF Harvest Water Inlet Dump Harvest Ice Thickness Length of Condenser Fan Water Pump OPERATION Valve Valve Valve Float Switch Float Switch Time Motor* Initial Start-up 45 seconds CLOSED CLOSED 1a.
  • Page 49 Until Harvest Float Switch OPEN THEN CLOSED THEN 4. Freeze closes for CLOSED OPEN 10 continual seconds Harvest Sequence 45 seconds 5. Water Purge CLOSED CLOSED Bin switch 6. Harvest activation CLOSED CLOSED Until 3 Minute CLOSED CLOSED 7. Automatic delay Shut-off expires and...

  • Page 50: Operational Checks

    Adjust to achieve a 1/8" (3 mm) bridge thickness. NOTE: The float can be adjusted with a 3/4" wrench while the water trough is in-place.Test run two cycles to verify ice bridge thickness. Ice Thickness Float Switch Adjustment Part Number STH045 8/15...

  • Page 51: Troubleshooting

    Canceling a test cycle: To cancel a test cycle press the test button a second time. Restarting a test cycle: The test cycle will restart each time the test button is pressed for a 3 second time period. Part Number STH045 8/15...

  • Page 52: Diagnosing An Ice Machine That Will Not Run

    OFF mode. Refer to toggle switch diagnostics when steps 1-3 test good. 5. Be sure Steps 1 – 4 were followed thoroughly. Intermittent problems are not usually related to the control board. Replace control board if toggle switch operation is correct. Part Number STH045 8/15...

  • Page 53: Ice Machine Does Not Cycle Into Harvest When Water Loses Contact With The Harvest Float Switch

    To allow the service technician to initiate a harvest cycle without delay, this feature is not used on the first cycle after moving the toggle switch to OFF and back to ON. HARVEST FLOAT SWITCH ICE THICKNESS FLOAT SWITCH Part Number STH045 8/15...
  • Page 54 The ice machine is in a 6 but the ice machine remains minute freeze lock - Cycle in the freeze cycle. on/off and retest. The harvest light stays off Replace the control board. and the ice machine remains in freeze. Part Number STH045 8/15...

  • Page 55: Ice Machine Cycles Into Harvest Before Water

    Refer to float switch diagnostics. 10 seconds into the freeze Replace the control board. cycle the ice machine cycles from freeze to harvest and the control board harvest light energizes. Part Number STH045 8/15...

  • Page 56: Ice Production Check

    If they match closely, determine if: Another larger ice machine is required. Relocating the existing equipment to lower the load conditions is required. Contact the local distributor for information on available options and accessories. Part Number STH045 8/15...

  • Page 57: Installation/Visual Inspection Checklist

    • Clean the condenser Water filtration is plugged (if used) • Install a new water filter Water drains are not run separately and/or are not vented • Run and vent drains according to the Installation Manual Part Number STH045 8/15...

  • Page 58: Water System Checklist

    Uneven water flow across the evaporator • Clean the ice machine Water is freezing behind the evaporator • Correct the water flow Plastic extrusions and gaskets are not secured to the evaporator • Remount/replace as needed Part Number STH045 8/15...

  • Page 59: Ice Formation Pattern

    This is normal. If ice forms uniformly across the evaporator surface, but does not do so in the proper amount of time, this is still considered a normal ice fill pattern. Part Number STH045 8/15...
  • Page 60 No Ice Formation The ice machine operates for an extended period, but there is no ice formation at all on the evaporator. Possible cause: water inlet valve, water pump, starving expansion valve, low refrigerant charge, compressor, etc. Part Number STH045 8/15...

  • Page 61: Safety Limits

    SL#2 light on the control board will flash on/off at 1 second intervals. • If 100 consecutive 3.5 minute harvest cycles occur, the ice machine stops and the SL#2 light on the control board will be on continuously. Part Number STH045 8/15...
  • Page 62 If 100 consecutive failures occur the ice machine stops and the SL#1 & SL#2 lights flash on/off at 1 second intervals. • SL#1 & SL#2 will flash 3 times on startup and automatically erase after 100 normal cycles. Part Number STH045 8/15...
  • Page 63 The control board will store and indicate only one safety limit – the last one exceeded. • If the toggle switch is cycled OFF and then ON prior to reaching the 100-harvest point, the last safety limit exceeded will be indicated. Part Number STH045 8/15...
  • Page 64 Compressor electrically non-operational • Restricted condenser air flow • High inlet air temperature (110°F/43.3°C max.) • Condenser discharge air re-circulation • Dirty condenser fins • Defective fan cycling control • Defective fan motor • Dirty condenser Part Number STH045 8/15...
  • Page 65 Non- OEM components • Improper refrigerant charge • Defective compressor • TXV starving or flooding (check bulb mounting) • Non-condensible in refrigeration system • Plugged or restricted high side refrigerant lines or component • Defective harvest valve Part Number STH045 8/15...
  • Page 66 Electrical system • Bin switch defective • Premature harvest Refrigeration system • Non-OEM components • Improper refrigerant charge • Defective harvest valve • TXV flooding (check bulb mounting) • Defective fan cycling control Part Number STH045 8/15...
  • Page 67 Low water pressure (20 psig min.) • Dirty defective water filter (when used) • Loss of water from sump area • Dirty/defective water inlet valve Electrical system • Water inlet valve coil defective • Harvest float valve defective Part Number STH045 8/15...

  • Page 68: Analyzing Discharge Pressure

    It is normal for the discharge pressure to be higher at the beginning of the freeze cycle (when load is greatest), then drop through out the freeze cycle. Part Number STH045 8/15...
  • Page 69 Wrong type of refrigerant Other • Non-OEM components in system • High side refrigerant lines/component restricted (before mid-condenser) • Defective fan cycle control NOTE: Do not limit your diagnosis to only the items listed in the checklists. Part Number STH045 8/15...

  • Page 70: Analyzing Suction Pressure

    NOTE: Analyze discharge pressure before analyzing suction pressure. High or low discharge pressure may be causing high or low suction pressure. Part Number STH045 8/15...
  • Page 71 In this example, the suction pressure is considered high throughout the freeze cycle. It should have been: Approximately 65 psig (at 1 minute) – not 79 Approximately 39 psig (at 7 minutes) – not 48 Approximately 26 psig (at 14 minutes) – not 40 Part Number STH045 8/15...
  • Page 72 High Checklist” on page 69. Improper Refrigerant Charge • Overcharged • Wrong type of refrigerant • Non-condensible in system Other • Non-OEM components in system • Harvest valve leaking • TXV flooding (check bulb mounting) • Defective compressor Part Number STH045 8/15...
  • Page 73 Loss of heat transfer from tubing on back side of evaporator • Restricted/plugged liquid line drier • Restricted/plugged tubing in suction side of refrigeration system • TXV starving NOTE: Do not limit your diagnosis to only the items listed in the checklists. Part Number STH045 8/15...

  • Page 74: Harvest Valve

    Exact pressures vary according to ambient temperature and ice machine model. Harvest pressures can be found in the Cycle Time/24 Hour Ice Production/ Refrigerant Pressure Charts in this book. Part Number STH045 8/15...
  • Page 75 As the amount of leakage increases the length of the freeze cycle increases and the amount of ice at the outlet of the evaporator decreases. Refer to the Parts Manual for proper valve application. If replacement is necessary, use only “original” replacement parts. Part Number STH045 8/15...
  • Page 76 The inlet of the harvest valve and the compressor discharge line could be hot enough to burn your hand. Just touch them momentarily. 4. Compare the temperature of the inlet of the harvest valves to the temperature of the compressor discharge line. Part Number STH045 8/15...
  • Page 77 This is not caused by a Cool & Cool harvest valve leaking. 5. Record your findings on the table. Part Number STH045 8/15...

  • Page 78: Comparing Evaporator Inlet/Outlet Temperatures

    Difference must be Outlet Temperature within 7°F (4°C) at Temperature 5 minutes into the freeze cycle 5. Use this with other information gathered on the Refrigeration System Operational Analysis Table to determine the ice machine malfunction. Part Number STH045 8/15...

  • Page 79: Discharge Line Temperature Analysis

    Connect a temperature probe on the compressor discharge line within 6" (15 cm) of the compressor. Observe the discharge line temperature for the last three minutes of the freeze cycle and record the maximum discharge line temperature. Part Number STH045 8/15...
  • Page 80 Verify the expansion valve sensing bulb is 100% insulated and sealed airtight. Condenser air contacting an incorrectly insulated sensing bulb will cause overfeeding of the expansion valve. Part Number STH045 8/15...

  • Page 81: Refrigeration Component Diagnostics

    The tables list four different defects that may affect the ice machine’s operation. NOTE: A low-on-charge ice machine and a starving expansion valve have very similar characteristics and are listed under the same column. Part Number STH045 8/15...
  • Page 82 Step 2 Add the check marks listed under each of the four columns. Note the column number with the highest total and proceed to “Final Analysis.” NOTE: If two columns have matching high numbers, a procedure performed properly and/or supporting material was not analyzed correctly. Part Number STH045 8/15...

  • Page 83: Final Analysis

    Column 4 – Compressor Replace the compressor and start components. To receive warranty credit, the compressor ports must be properly sealed by crimping and soldering them closed. Old start components must be returned with the faulty compressor. Part Number STH045 8/15...

  • Page 84: Refrigeration Component Diagnostic Chart

    Refrigeration Component Diagnostic Chart Part Number STH045 8/15...
  • Page 85 Part Number STH045 8/15...
  • Page 86 Part Number STH045 8/15...

  • Page 87: Component Check Procedures

    Warning Disconnect electrical power to the entire ice machine before proceeding. 2. Remove the fuse. Check the resistance across the fuse with an ohmmeter. Reading Result Open (OL) Replace fuse Closed (O) Fuse is good Part Number STH045 8/15...

  • Page 88: Bin Switch

    The bin switch must close. The curtain light “on” indicates the bin switch has closed properly. 4. Close the water curtain. The bin switch must open. The curtain light “off” indicates the bin switch has opened properly. Part Number STH045 8/15...
  • Page 89 Always use the water curtain magnet to cycle the switch (a larger or smaller magnet will affect switch operation). • Watch for consistent readings when the bin switch is cycled open and closed (bin switch failure could be erratic). Part Number STH045 8/15...

  • Page 90: Float Switch

    A. The light must be on in the up position. B. The light must be off in the down position. Ice Thickness Float Switch: A. The light must be on in the up position. B. The light must be off in the down position. Part Number STH045 8/15...
  • Page 91 NOTE: Make adjustments with the ice machine in the off position. Making adjustments during the freeze cycle may produce an initial sheet of ice that is thicker than future cycles. HARVEST FLOAT THICKNESS SWITCH FLOAT Part Number STH045 8/15...

  • Page 92: Compressor Electrical Diagnostics

    If continuity is present, the compressor windings are grounded and the compressor should be replaced. To determine if the compressor is seized check the amp draw while the compressor is trying to start. Part Number STH045 8/15...
  • Page 93 The wiring must be correctly sized to minimize voltage drop at compressor start-up. The voltage when the compressor is trying to start must be within 10% of the nameplate voltage. Part Number STH045 8/15...

  • Page 94: Fan Cycle Control

    Reconnect electrical power to the ice machine and Cycle the toggle switch On. Wait until water flows over the evaporator then refer to chart below. System Reading Fan Should Should Be: Pressure: above cut-in 0 volts running below cut-out line voltage Part Number STH045 8/15...

  • Page 95: High Pressure Cutout (Hpco) Control

    HPCO control does not cut out, cycle the toggle switch Off to stop ice machine operation. Replace the HPCO control if it: • Will not reset (below 450 psig) • Does not open at the specified cut-out point Part Number STH045 8/15...

  • Page 96: Refrigeration Components

    NOTE: When a head pressure control valve is being replaced or refrigerant charge is suspected, verify the refrigerant charge is correct by recovering the refrigerant, weighing and comparing to the nameplate amount. Refer to Refrigerant Recovery/Evacuation for recovery procedures. Part Number STH045 8/15...
  • Page 97 “Cycle Times/24-Hour Ice Production/ Refrigerant Pressure Charts”). 4. Determine the temperature of the liquid line entering the receiver by feeling it. This line is normally warm; “body temperature.” 5. Using the information gathered, refer to the chart. Part Number STH045 8/15...
  • Page 98 Liquid Line Temperature - bypass valve Discharge Pressure - Low Valve not Replace Liquid Line Temperature - bypassing valve Cold Discharge Pressure - Low Ice Machine Refrigerant Liquid Line Temperature - Low on Charge Charge Verification Part Number STH045 8/15...
  • Page 99 The sheet of ice cubes show little or no sign of melting when removed from the evaporator after the harvest cycle has been completed. (If the cubes are melted you have a release problem, clean the ice machine). Part Number STH045 8/15...

  • Page 100: Harvest Pressure Regulating (Hpr) System Remote Condenser Only

    The valve closes completely and stops refrigerant flow when the pressure at the outlet rises above the valve setting. INLET OUTLET HPR VALVE Part Number STH045 8/15...
  • Page 101 3. Freeze time normal?  (Refer to Cycle Times/Refrigerant Pressures/24 Hour Ice Production Charts). Shorter freeze cycles - Refer to head pressure control valve diagnostics. Longer freeze cycles - Refer to water system checklist, then refer to Refrigeration Diagnostic Procedures. Part Number STH045 8/15...
  • Page 102 Refer to analyzing suction pressure if suction pressure is high or low. 9. Harvest cycle suction and discharge pressures are lower than indicated in the cycle times/ refrigerant pressures/24 hour ice production chart? 10. Replace Harvest Pressure Regulating solenoid. Part Number STH045 8/15...

  • Page 103: Water Regulating Valve

    Discharge pressure extremely high; Liquid line entering receiver feels hot. • Water regulating valve incorrectly set or not opening. Discharge pressure low, Liquid line entering receiver feels warm to hot. Ice machine low on charge. • Verify Total System Refrigerant Charge Part Number STH045 8/15...

  • Page 104: Refrigerant Recovery/Evacuation

    “reclaimed” unless it has been chemically analyzed and meets ARI Standard 700 (latest edition). New Product Specifications This means ARI Standard 700 (latest edition). Chemical analysis is required to assure that this standard is met. Part Number STH045 8/15...

  • Page 105: Refrigerant Re-Use Policy

    REFRIGERANT RE-USE POLICY Koolaire recognizes and supports the need for proper handling, re-use, and disposal of refrigerants. Koolaire service procedures require recapturing refrigerants, not venting them to the atmosphere. It is not necessary, in or out of warranty, to reduce or compromise the quality and reliability of your customers’...
  • Page 106 • Refer to “Remote Condenser Model Procedure” on page 110 to test for contamination. 5. “Substitute” or “Alternative” Refrigerant • Must use only Koolaire-approved alternative refrigerants. • Must follow Koolaire-published conversion procedures. Part Number STH045 8/15...

  • Page 107: Recovery And Recharging Procedures

    Do not purge refrigerant to the atmosphere. Capture refrigerant using recovery equipment. Follow the manufacturer’s recommendations. Important Koolaire assumes no responsibility for the use of contaminated refrigerant. Damage resulting from the use of contaminated refrigerant is the sole responsibility of the servicing company.
  • Page 108 B. Evacuation prior to recharging: Pull the system down to 500 microns. Then, allow the pump to run for an additional half hour. Turn off the pump and perform a standing vacuum leak check. Part Number STH045 8/15...
  • Page 109 CHARGING PROCEDURES Important The charge is critical on all Koolaire machines. Use a scale or a charging cylinder to ensure the proper charge is installed. 1. Cycle the toggle switch Off. 2. Close the vacuum pump valve, the low side manifold gauge valve.

  • Page 110: Remote Condenser Model Procedure

    Access (access) valve on the discharge line quick- connect fitting, located on the outside of the compressor/evaporator compartment. This connection evacuates the condenser. Without it, the magnetic check valves would close when the pressure drops during evacuation, preventing complete evacuation of the condenser. Part Number STH045 8/15...
  • Page 111 Turn off the pump and perform a standing vacuum leak check. NOTE: Check for leaks with an electronic leak detector after charging the ice machine. 5. Follow the Charging Procedures. Part Number STH045 8/15...
  • Page 112 5. Allow the pressures to equalize while the ice machine is in the freeze cycle. 6. Remove the low side hose from the access valve and install the caps. Part Number STH045 8/15...

  • Page 113: System Contamination Cleanup

    This section describes the basic requirements for restoring contaminated systems to reliable service. Important Koolaire assumes no responsibility for the use of contaminated refrigerant. Damage resulting from the use of contaminated refrigerant is the sole responsibility of the servicing company.
  • Page 114 No burnout deposits in open compressor lines Severe Compressor Burnout symptoms Severe Oil is discolored, acidic, and smells contamination acrid cleanup Burnout deposits found in the procedure compressor, lines, and other components Part Number STH045 8/15...

  • Page 115: Mild System Contamination Cleanup Procedure

    You should use an electronic leak detector after system charging to be sure there are no leaks. 5. Charge the system with the proper refrigerant to the nameplate charge. 6. Operate the ice machine. Part Number STH045 8/15...

  • Page 116: Severe System Contamination Cleanup Procedure

    Repeat until the pressure drop is acceptable. 12. Operate the ice machine for 48 – 72 hours. Replace the suction line and liquid line drier if necessary. 13. Follow normal evacuation procedures. Part Number STH045 8/15...

  • Page 117: Replacing Pressure Controls Without Removing Refrigerant Charge

    Tighten the wing nuts until the block is tight and the tubing is rounded. NOTE: The pressure controls will operate normally once the tubing is re-rounded. Tubing may not re-round 100%. Part Number STH045 8/15...
  • Page 118 FIG. A - “PINCHING OFF” TUBING FIG. B - RE-ROUNDING TUBING SV1406 Using Pinch Off Tool Part Number STH045 8/15...

  • Page 119: Refrigerant Amount

    Refrigerant Amount Additional Remote Refrigerant amount Model air-cooled Water-cooled Air-cooled for 51’ to 100’ Line Sets K0250 60Hz - 0.9375lbs 50 Hz - 1.0625 lbs K0350 60Hz - 1.125 lbs 0.875 lbs 50 Hz - 1.3125 lbs K0420 1.0 lbs 0.875 lbs K0500 1.125 lbs...
  • Page 120 This Page Intentionally Left Blank Part Number STH045 8/15...

  • Page 121: Cycle Times, 24 Hr. Ice Production And Refrigerant Pressure Charts

    Discharge and suction pressure are highest at the beginning of the cycle. Suction pressure will drop throughout the cycle. Verify the pressures are within the range indicated. • Record beginning of freeze cycle suction pressure one minute after the water pump energizes. Part Number STH045 8/15...

  • Page 122: K0250A Self-Contained Air-Cooled

    70-38 160-180 150-175 70/21 310-340 75-40 180-200 150-175 80/27 315-360 80-42 185-210 150-175 90/32 320-375 90-44 190-215 150-175 100/38 420-510 100-49 300-330 200-250 110/43 450-540 120-52 355-370 270-290 Suction pressure drops gradually throughout the freeze cycle Part Number STH045 8/15...

  • Page 123: K0350A Self-Contained Air-Cooled

    55-32 130-200 90-140 70/21 275-340 60-33 150-200 100-140 80/27 285-395 65-34 170-230 105-165 90/32 335-410 70-35 190-250 110-175 100/38 400-500 80-40 280-340 160-220 110/43 450-520 85-42 320-360 190-235 Suction pressure drops gradually throughout the freeze cycle Part Number STH045 8/15...

  • Page 124: K0350W Self-Contained Water-Cooled

    60-34 150-210 110-150 70/21 315-330 60-34 150-210 110-150 80/27 315-330 60-34 150-210 110-150 90/32 315-330 60-34 150-210 110-150 100/38 315-335 60-34 150-210 110-150 110/43 315-340 65-36 150-210 110-150 Suction pressure drops gradually throughout the freeze cycle. Part Number STH045 8/15...

  • Page 125: K0420A Self-Contained Air-Cooled

    60-31 180-220 130-160 70/21 290-380 65-32 200-220 140-160 80/27 300-390 65-33 215-235 150-170 90/32 330-400 70-34 235-245 160-180 100/38 400-500 80-34 355-370 240-270 110/43 430-520 95-34 370-375 255-275 Suction pressure drops gradually throughout the freeze cycle Part Number STH045 8/15...

  • Page 126: K0420W Self-Contained Water-Cooled

    70-31 155-230 110-165 70/21 325-335 70-31 155-235 110-170 80/27 325-335 70-31 160-240 110-170 90/32 325-335 75-31 160-245 110-175 100/38 325-345 80-31 160-245 115-180 110/43 325-350 80-31 160-245 115-180 Suction pressure drops gradually throughout the freeze cycle. Part Number STH045 8/15...

  • Page 127: K0500A Self-Contained Air-Cooled

    60-36 140-175 100-120 70/21 270-340 65-37 150-185 105-130 80/27 275-380 65-37 165-200 110-150 90/32 340-400 75-38 190-220 130-160 100/38 380-500 80-42 280-320 180-235 110/43 440-520 80-44 290-330 185-240 Suction pressure drops gradually throughout the freeze cycle Part Number STH045 8/15...

  • Page 128: K0500W Self-Contained Water-Cooled

    70-38 145-175 105-130 70/21 325-335 70-39 150-180 110-135 80/27 325-335 75-39 150-185 110-135 90/32 325-340 80-39 150-190 110-135 100/38 325-340 80-39 150-190 110-135 110/43 325-345 80-39 150-190 110-135 Suction pressure drops gradually throughout the freeze cycle Part Number STH045 8/15...

  • Page 129: K0600A Self-Contained Air-Cooled

    60-28 140-175 90-120 70/21 275-350 65-30 165-200 100-130 80/27 275-380 70-31 165-210 105-150 90/32 350-415 75-35 310-370 170-215 100/38 380-520 80-36 310-375 170-235 110/43 440-540 80-36 310-375 170-225 Suction pressure drops gradually throughout the freeze cycle Part Number STH045 8/15...

  • Page 130: K0600W Self-Contained Water-Cooled

    55-31 160-210 100-135 70/21 300-325 55-32 180-225 100-140 80/27 300-325 60-32 180-230 105-140 90/32 300-325 65-32 180-230 105-140 100/38 300-325 65-32 180-230 105-140 110/43 300-325 65-32 180-230 105-140 Suction pressure drops gradually throughout the freeze cycle Part Number STH045 8/15...

  • Page 131: K1000A Self-Contained Air-Cooled

    60-28 140-200 100-140 70/21 300-390 65-28 145-200 105-140 80/27 320-400 70-32 150-205 105-150 90/32 350-415 75-33 160-210 110-150 100/38 450-520 80-37 170-240 115-155 110/43 440-540 85-39 200-250 125-160 Suction pressure drops gradually throughout the freeze cycle Part Number STH045 8/15...

  • Page 132: K1000W Self-Contained Water-Cooled

    65-30 140-220 100-155 70/21 295-310 65-30 140-220 100-155 80/27 295-310 65-32 145-225 100-160 90/32 295-310 65-32 150-225 105-160 100/38 300-330 68-33 150-230 105-165 110/43 310-345 70-34 150-235 105-165 Suction pressure drops gradually throughout the freeze cycle Part Number STH045 8/15...

  • Page 133: K1000N Remote Air-Cooled

    60-36 190-210 110-130 70/21 310-365 60-38 200-220 120-140 80/27 315-370 65-38 205-225 120-150 90/32 320-375 65-38 210-225 130-150 100/38 380-500 70-45 220-250 135-155 110/43 405-520 75-46 230-250 140-160 Suction pressure drops gradually throughout the freeze cycle Part Number STH045 8/15...

  • Page 134: K1350A Self-Contained Air-Cooled

    165-190 125-135 70/21 300-380 66-34 165-190 125-135 80/27 315-410 73-36 175-205 130-140 90/32 330-450 81-39 185-220 135-150 100/38 375-490 91-42 200-240 150-170 110/43 420-530 101-46 230-260 165-185 1 Suction pressure drops gradually throughout the freeze cycle Part Number STH045 8/15...

  • Page 135: K1350W Self-Contained Water-Cooled

    160-180 110-130 110/43 310-340 74-44 165-185 115-130 1 Suction pressure drops gradually throughout the freeze cycle 2 Water regulating valve set to maintain 300 psig 3 Condenser Water Usage = 160 gal/100 lb ice @ 90°/70°F Part Number STH045 8/15...

  • Page 136: K1350N Remote Air-Cooled

    165-190 115-140 70/21 300-365 70-33 165-190 115-140 80/27 305-370 75-35 170-190 115-140 90/32 305-380 75-38 170-195 120-145 100/38 330-410 82-42 175-195 125-145 110/43 400-490 95-48 180-200 130-150 1 Suction pressure drops gradually throughout the freeze cycle Part Number STH045 8/15...

  • Page 137: Wiring Diagrams

    Fan Motor Run Capacitor (Some models do not incorporate fan motor run capacitor) Wire Number Designation (The number is marked at each end of the wire) —>>— Multi-pin Connection (Electrical Box Side) —>>— (Compressor Compartment Side) Part Number STH045 8/15...

  • Page 138: K0250, K0350, K0420, K0500, K0600, K1000  Self Contained Air Or Water-Cooled

    K0250, K0350, K0420, K0500, K0600, K1000  SELF CONTAINED AIR OR WATER-COOLED Part Number STH045 8/15...

  • Page 139: K1000 Remote Air-Cooled

    K1000 REMOTE AIR-COOLED Part Number STH045 8/15...

  • Page 140: K13500 - K1800 Air Or Water-Cooled

    K13500 - K1800 AIR OR WATER-COOLED 230V/50-60 Hz/1Ph Part Number STH045 8/15...

  • Page 141: K13500 - K1800 Air Or Water-Cooled

    K13500 - K1800 AIR OR WATER-COOLED 230V/50-60 Hz/3Ph Part Number STH045 8/15...

  • Page 142: K13500 - K1800 Remote Air-Cooled

    K13500 - K1800 REMOTE AIR-COOLED 230V/50-60 Hz/1Ph Part Number STH045 8/15...

  • Page 143: K13500 - K1800 Remote Air-Cooled

    K13500 - K1800 REMOTE AIR-COOLED 230V/50-60 Hz/3Ph Part Number STH045 8/15...

  • Page 144: Electronic Control Board

    ELECTRONIC CONTROL BOARD Part Number STH045 8/15...

  • Page 145: Refrigeration Tubing Schematics

    Refrigeration Tubing Schematics SELF-CONTAINED AIR OR WATER-COOLED EVAPORATOR HEAT EXCHANGER EXPANSION VALVE HARVEST SOLENOID VALVE STRAINER DRIER AIR OR WATER RECEIVER COMPRESSOR CONDENSER (WATER COOLED ONLY) Part Number STH045 8/15...

  • Page 146: Remote Air-Cooled

    REMOTE AIR-COOLED Part Number STH045 8/15...
  • Page 148 Koolaire 2110 South 26th Street, P.O. Box 1720 © 2014 Koolaire Manitowoc, WI 54221-1720, USA Part Number STH045 8/15 Ph: 920-682-0161 Fax: 920-683-7589 Visit us online at: www.kool-aire.com...

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